Elongated Foam Sheet Pasting for Precise Thickness Control
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Solution Overview
Problem
Existing methods for manufacturing elongated foam sheets are limited by the material and thickness of the foam material, making it difficult to achieve precise thickness and successive processing, such as punching and pasting to elongated roll materials.
Innovation Solution
A method involving sheet pasting, where a large number of foam sheets are arranged and pasted onto an elongated base material sheet, followed by processes like slicing, stretching, and inspection to create an elongated foam sheet with precise thickness, and then cutting into plate-shaped flakes for composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a cylindrical foam block is sliced to manufacture an elongated foam sheet, then the foam sheet can be produced, but the thickness precision and material adaptability are extremely limited
Solution Approach 1:
The patent divides the elongated foam sheet into multiple individual foam sheets arranged in parallel, which are then pasted together. This segmentation allows each individual sheet to be precisely controlled in thickness while the combined structure achieves the desired elongated form, resolving the contradiction between thickness precision and material adaptability
Solution Approach 2:
The patent transitions from slicing in one dimension (cylindrical block) to arranging multiple sheets in a two-dimensional array that is then rolled into an elongated form. This dimensional transformation enables precise thickness control of individual sheets while achieving versatile material configurations
2Ease of manufacture
If individual foam sheets are used, then the foam sheets can be manufactured, but successive processing such as punching and pasting to elongated roll materials becomes difficult
Solution Approach 1:
The patent combines multiple individual foam sheets into a unified elongated foam sheet structure by pasting them together on a base material sheet. This merging enables successive processing operations to be performed continuously on the combined structure, significantly improving productivity while maintaining the manufacturability of individual sheets
Solution Approach 2:
The patent introduces a base material sheet as an intermediary substrate onto which individual foam sheets are pasted. This intermediary enables easy handling, alignment, and successive processing of the foam sheets, resolving the difficulty of processing individual sheets while maintaining manufacturing ease
Data Source
AI summary
In order to provide a manufacturing method of an elongated foam sheet capable of manufacturing the elongated foam sheet with highly-precise thickness without being limited by the material and thickness of foam material, a method of manufacturing an elongated foam sheet includes performing a slice process in which a foam sheet is created by slicing a foam block and a sheet pasting process in which a large number of foam sheets are arranged and pasted onto one side of an elongated base material sheet to manufacture the elongated foam sheet where the large number of foam sheets are lined up in a longitudinal direction of the base material sheet.